BMW R 1150 R Maintenance Manual

Brand: BMW

Model: R 1150 R

Category: Motorcycles

Type: Maintenance Manual

This manual is also suitable for

BMW Motorrad

After Sales

R 1150 R

Maintenance BMW Integral ABS

Published by: © BMW Motorrad

After Sales

UX-VS-2

permission.

Errors and omissions excepted; subject to technical amendment.

Produced in Germany 01/01

Order No. 01 71 0 029 614 UX-VS-2, 12.2000 Printed in Germany

Customer Registration No.

Order No. Mechanic’s signature

BMW Inspection

at 1,000 km

(600 miles)

BMW Service

10,000 km

(6,000 miles)

BMW Inspection

every 20,000 km

(12,000 miles)

BMW

Annual Service

Read the fault code memory with the BMW MoDiTeC

[Integral ABS] perform bleed test with BMW MoDiTeC

Change oil while at regular operating temperature and replace the oil filter element

If the motorcycle is ridden only for short distances or outside temperatures are below 0 °C: at the

latest every 3,000 km (1,800 miles)*

)

Change oil in gearbox while at operating temperature

every 2 years*

)

at the latest

every

2years

Change oil in rear wheel drive while at operating temperature

if necessary, clean inductive sensor on rear wheel

every 40,000 km (24,000 miles) or at the latest every 2 years*

)

40,000

every

2years

Replace fuel filter *

)

Normally every 40,000 km (24,000 miles), if fuel is of poor quality every 20,000 km (12,000 miles)

40,000

Check the battery fluid level, if necessary top up with distilled water

Clean and grease battery poles if necessary

Replace intake air filter element

In very dirty and dusty operating conditions, replace every 10,000 km (6,000 miles) or even more

frequently if necessary *

)

Replace Poly-V belt *

)

Replace the Poly-V belt every 60,000 km (36,000 miles); do not adjust it 60,000

Check brake fluid level at front and rear

Check operation of brake system and freedom from leaks; repair/replace items if necessary*

)

Examine brake pads and discs for wear, replace as necessary*

)

[Without ABS] change brake fluid every twelve months

[Integral ABS] change bake fluid in wheel circuit every 12 months

[Integral ABS] change brake fluid in control circuit every 2 years*

)

every

2years

[Integral ABS] perform bleed test with BMW MoDiTeC

Check clutch fluid level

Change the clutch fluid*

)

every 2 years at the latest

every

2years

Check tightness of rear wheel studs

Check rear wheel bearing play by tilting wheel

Check swinging arm bearings (freedom from play), adjust if necessary *

)

Grease the side stand pivot

Check function of side stand contact switch

Check condition of spark plugs

Replace spark plugs

Tighten cylinder head nuts

Check/adjust valve clearances

Check that the throttle cable moves freely and is free of kinks and chaffing, replace if necessary *

)

Check throttle-cable play

check synchronisation, repair leaks if necessary *

)

Final inspection with road safety and functional check:

– Condition of tyres and wheels, tyre pressures

– Lights and signalling equipment, telltale and warning lights, instruments,

– clutch, gearshift mechanism, hand brake and foot brake, steering,

– if necessary, test drive

)

Charged as an additional item

BMW Motorrad

Maintenance schedule

R 1100 S EVO / R 1150 R / R 1150 RT

Order No. 01 71 0 029 614 UX-VS-2, 12.2000 Printed in Germany

Customer Registration No.

Order No. Mechanic’s signature

BMW

Pre-delivery check

Check the shipping crate for damage

Motorcycle:

– unpack

– install remaining items

– inspect for damage

– check that delivery is complete: Toolkit

On-board literature

Ignition keys

Scope of optional extras

Fill and charge the battery (mark with charging date)

Check engine oil level when cold and correct if necessary.

Check headlight setting and adjust if necessary.

Check tightness of rear wheel studs

(note correct tightening torque)

Check tyre pressures

Fill up with fuel

[Integral ABS] perform bleed test with BMW MoDiTeC

Final inspection as functional check:

– Clutch, gear shift

– Handbrake and foot brake

– Lights and signalling equipment, telltale and warning lights, instruments,

– Check operation of optional extras

– If necessary, test drive

Confirm pre-delivery check in “Service and Technical Booklet”.

Final cleaning

Motorcycle handed over on:

BMW Motorrad

Pre-delivery check

R 1100 S EVO / R 1150 R / R 1150 RT

Order No. 01 71 0 026 973 UX-VS-2, 07.00 Printed in Germany

Item Desired value Unit of measure-

ment/specification

Oil capacities

Engine (with filter)

(without filter)

Transmission Initial filling

Oil changes

Rear wheel drive Initial filling/oil change

3.75 (6.6)

3.50 (6.15)

approx. 1.0 (1.76)

approx. 0.8 (1.41)

of oil to bottom edge of

filler neck

approx. 0.25 (0.44)

of oil to bottom edge of

filler neck

litres (Imp. pints)

[SI 11 048 90]

Engine oil grade: brand-name HD oil

for four-stroke spark-ignition engines,

API classes SE, SF, SG; combination

with CC or CD specification

litres (Imp. pints)

Brand-name hypoid gear oil, SAE

class GL 5 SAE 90

litres (Imp. pints)

Brand-name hypoid gear oil, SAE

class GL 5 SAE 90

Valve clearances

measured cold (max. 35 °C/95 °F)

Inlet: 0.15 (0.006)

Exhaust: 0.30 (0.012)

mm (in)

Ignition timing

static setting

adjust at TDC

Spark plugs

Electrode gap

Wear limit

0.8 (0.0315)

1.0 (0.039)

mm (in)

Idle speed

1,100

±50

rpm

Throttle cable setting

for cold-start (increased idle) speed

for throttle (twistgrip) cable

for divider cable

zero play

approx. 0.5 (0.02)

zero play

mm (in) free travel

Brakes

Colour of identification mark on brake calipers/brake pads, front

Minimum front pad thickness

Minimum rear pad thickness

Minimum front disc thickness

Minimum rear disc thickness

green

1.0 (0.039)

1.0 (0.039) (wear mark)

4.5 (0.177)

DOT 4 brake fluid

mm (in)

Ty r e p r e s su r e s

depending on load

front: 2.2 – 2.5

(31.9 – 36.26)

rear: 2.5 – 2.9

(36.26 – 42.06)

bar (psi)

Tightening torques:

Oil filter

Engine oil drain plug

Gearbox oil filler plug

Gearbox oil drain plug

Rear wheel drive oil filler/drain plug 23 Nm

Fuel tank to rear frame

Fuel pump assembly to tank

Poly-V belt preload

Alternator to cover mount

Brake caliper fasteners, front

Brake caliper fasteners, rear

Rear wheel studs 105 Nm

Tightening cylinder heads

Nut

M 10 screw

unscrew/20

180

unscrew/40

° tightening angle

Locknut, valve adjusting screw 8 Nm

Cylinder head cover 8 Nm

Spark plugs NGK BKR 7 EKC 25 Nm

BMW Motorrad

Service data

R 1150 R

00.1

Contents Page

Tightening torque .........................................................................................................................3

11 Engine ...........................................................................................................................................3

12 Engine electrics ........................................................................................................................5

13 Fuel preparation and control ...............................................................................................5

16 Fuel tank and lines ...................................................................................................................5

18 Exhaust system .........................................................................................................................6

21 Clutch ............................................................................................................................................6

23 Transmission ..............................................................................................................................7

31 Front fork ......................................................................................................................................7

32 Steering ........................................................................................................................................8

33 Rear wheel drive .......................................................................................................................8

34 Brakes ...........................................................................................................................................9

36 Wheels and tyres ....................................................................................................................10

46 Frame ..........................................................................................................................................10

51 Equipment .................................................................................................................................11

61 General electrical equipment ............................................................................................ 11

Table of operating fluids .........................................................................................................12

00 Tightening torque

Table of operating fluids

00.2

00.3

Tightening torque

Model R 1150 R

Connection

11 Engine

Cylinder head

Tightening sequence:

1Tighten cylinder head nuts (oiled) in go-

nally opposite sequence

1.1 Tighten all nuts to closing torque Nm 20

1.2 Tighten all nuts to correct angle ° 90

1.3 Tighten all nuts to correct angle ° 90

2M 10 screw Nm 40

3M6 screw Nm 9

After 1,000 km (600 miles), tighten cylinder

head nuts in diagonally opposite se-

quence:

1Slacken one nut

2Tighten nut to initial torque Nm 20

3 Tighten nut to wrench angle ° 180

4Slacken and retighten M10 screw Nm 40

Timing gear carrier to cylinder head Nm

Bearing cap on rocker shaft Nm 18

Locknut, valve adjusting screw Nm 8

Cylinder head cover to cylinder head Nm 8

Camshaft end cover to cylinder head Nm

Air intake connection to cylinder head Nm

Camshaft

Chain sprocket to camshaft Nm 65

Camshaft bearing cap Nm 15

Alternator mount cover

M 6 screw Nm 9

M 8 screw Nm 20

Auxiliary shaft

Chain sprocket to crankshaft Nm 10

Chainwheel to auxiliary shaft Nm 70

Chain tensioner housing to engine block Nm 9

00.4

Oil filter

Oil filter Nm 11

Oil drain plug Nm 32

Oil pump

Mesh filter basket to engine block Nm 10

Oil pump cover Nm 9

Pressure relief valve Nm 42

Oil pressure switch Nm 30

Oil cooler

Cooling oil line to engine block Nm 10

Cooling oil line - banjo screw with oil vent

valve

Nm 25

Oil lines to oil cooler Nm 25

Oil cooler to bracket Nm 8

Oil cooler return line to engine block Nm 35

Oil cooler connection to crankcase Nm 9

Cylinders

Tightening sequence:

1M 8 screw Nm 20

2M 6 screw Nm 9

3Chain guide rail pivot screw Nm 18

Timing chain

Chain tensioner Nm 32

Connecting rod

Big end cap

Closing torque Nm 20

Wrench angle ° 80

Crankcase

Tightening sequence:

M 10 screw (oiled) to initial torque Nm 25

Wrench angle ° 90

M 8 screw Nm 22 (oiled)

M6 screw Nm 9

Model R 1150 R

Connection

11 Engine

00.5

Model R 1150 R

Connection

12 Engine electrics

Starter motor to engine Nm 20

Starter cover to gearbox housing Nm 7

Positive lead to starter motor Nm 10

Alternator to alternator support cover Nm 20

Tensioning and retaining link to alternator Nm 21

Spacer to alternator Nm 21

Positive lead to alternator Nm 15

Belt pulley to alternator Nm 50

Belt pulley to crankshaft Nm 50

Poly-V belt preload Nm 8

Spark plug NGK BKR 7 EKC Nm 25

Model R 1150 R

Connection

13 Fuel preparation and control

Temperature sensor, oil, in crankcase Nm 25

Temperature sensor, air, in air-filter housing Nm 10

Model R 1150 R

Connection

16 Fuel tank and lines

Fuel tank to rear frame Nm 22

Fuel pump assembly to tank Nm 5

00.6

Model R 1150 R

Connection

18 Exhaust system

Manifold to cylinder head Nm 21

Clamp for manifold Nm 45

(apply Optimoly TA to clamp seat)

Front silencer to manifold Nm 45

(apply Optimoly TA to clamp seat)

Silencer to main stand lugs Nm 20

Silencer to rear frame at top Nm 35

Oxygen sensor to silencer Nm 45

(apply Optimoly TA to thread)

End cap to rear silencer Nm 8

(threads greased)

Bracket to rear silencer Nm 15

(threads greased)

Model R 1150 R

Connection

21 Clutch

Clutch housing

Closing torque Nm 40

(oil screw threads lightly)

Wrench angle °

Housing cover to housing Nm 12

Clutch line to handlebar fitting Nm 14

Slave cylinder to gearbox Nm 9

Grub screw in filler adapter Nm 10

00.7

Model R 1150 R

Connection

23 Transmission

Oil drain plug Nm 30

Oil filler plug Nm 30

Gearbox to engine block Nm 22

Shift lever to footrest plate Nm 35

Selector lever to selector shaft Nm 9

Housing cover to housing Nm 9

Frame tube to gearbox

1. to gearbox and left footrest plate Nm 42

(clean thread + Loctite 243)

2. clamp block, frame tube to gearbox Nm 9

3. to gearbox and right footrest plate Nm 42

(clean thread + Loctite 243)

Model R 1150 R

Connection

31 Front fork

Quick-release axle clamp screws Nm 22

Clamp, fork fixed tube to fork bridge Nm 45

(free from oil and grease)

Slider tube bridge to slider tube Nm 25

(clean thread + Loctite 243)

Threaded stud to frame Nm 130

(clean thread + Loctite 243)

Ball joint to sliding tube bridge Nm 230

(lightly grease threads with Optimoly TA)

Leading link to ball joint

Initial tightening Nm 80

Final tightening Nm 130

(clean thread + Loctite 2701)

Leading link to engine Nm 130

Spring strut to front frame Nm 43

Spring strut to leading link Nm 50

00.8

Model R 1150 R

Connection

32 Steering

Handlebars to fork bridge, tightening se-

quence:

1. Front fastener (as viewed in forward

direction of travel) until seated

Nm 21

2. Rear fastener (as viewed in forward

direction of travel)

Nm 21

Handlebar weight to handlebars Nm 21

Pivot screw, handlebar lever Nm 11

(Tuflok Blue thread-locking compound; screw

can be released and tightened a number of

times)

Model R 1150 R

Connection

33 Rear wheel drive

Oil filler plug Nm 23

Oil drain plug Nm 23

Threaded ring Nm 160

(clean thread + Loctite 577)

Hexagon nut, input bevel gear Nm

200

(clean thread + Loctite 2701)

Cover to rear-wheel drive housing Nm 35

Fixed bearing stud bolt, swinging arm to

gearbox

Nm 160

Floating bearing stud bolt, swinging arm to

gearbox

1. initial torque Nm 9

2. slacken

3. final torque Nm 7

Locknut, floating bearing stud bolt,

swinging arm to gearbox

Nm 160

Fixed bearing stud bolt,

swinging arm to rear axle housing

Nm 160

(clean thread + Loctite 2701)

Floating bearing stud bolt,

swinging arm to rear axle housing

1. initial torque Nm 9

2. slacken

3. final torque Nm 7

Locknut, floating bearing stud bolt,

swinging arm to rear axle housing

Nm 160

(clean thread + Loctite 2701)

00.9

Reaction link to rear wheel drive / gearbox Nm 43

(load approx. 85 kg (187 lbs) onto motorcycle

and tighten loose reaction link)

Spring strut to rear frame Nm 50

Spring strut to rear swinging arm Nm 58

(clean thread + Loctite 243)

Hydraulic spring preload adjuster to foot-

rest plate

Nm 22

Model R 1150 R

Connection

34 Brakes

Brake caliper to fork slider tube, Evo

brakes

Nm 30

Brake caliper to rear wheel drive Nm 40

Brake disc to front wheel Nm 21

(clean thread + Loctite 2701)

Brake disc to rear wheel drive Nm 21

(clean thread + Loctite 2701)

Master cylinder to footrest assembly Nm 9

Footbrake lever to footrest assembly Nm

(clean thread + Loctite 2701)

Footbrake-lever stop Nm

Ball socket to thrust rod Nm

Brake lines/brake hose to brake compo-

nents

Brake hose to bracket Nm

Brake hose to brake lever fitting Nm 18

Bracket to front frame Nm 9

Bracket to rear frame Nm 9

(clean thread + Loctite 2701)

Front brake caliper bleed screw Nm

Rear brake caliper bleed screw Nm

Filler adapter to brake line Nm 18

ABS hydraulic unit to bracket Nm

ABS hydraulic unit to battery carrier Nm

Model R 1150 R

Connection

33 Rear wheel drive

00.10

Model R 1150 R

Connection

36 Wheels and tyres

Quick-release axle clamp screws Nm 22

Quick-release axle threaded fastener Nm 30

Rear wheel to rear wheel drive

Hand-tighten wheel studs and tighten in

diagonally opposite sequence

[Integral ABS] Note spacer

Nm 105

Model R 1150 R

Connection

46 Frame

Frame to engine Nm 82

Struts to frame Nm 58

Strut to engine Nm 58

(clean thread + Loctite 2701)

Rear frame to gearbox/engine

to gearbox and footrest plate Nm 42

(clean thread + Loctite 2701)

to engine Nm 42

Carrier plate for main stand to engine, right

M 12 screw Nm 72

(clean thread + Loctite 2701)

Pivot mount to engine, left

M 12 screw Nm 72

(clean thread + Loctite 2701)

M 8 screw Nm 21

Pivot mount of main (centre) stand (stud bolt) Nm 21

(clean thread + Loctite 243)

Pivot mount of main (centre) stand (ma-

chine screw)

Nm 21

Side stand to pivot mount Nm 58

(clean thread + Loctite 2701)

Footrest plate to gearbox Nm 21

Rear footrest plate to rear frame Nm 21

Front mudguard to fork slider tube bridge Nm 6

(Tuflok Blue thread-locking compound; screw

can be released and tightened a number of

times

alternatively: clean thread + Loctite 243)

00.11

Front and rear sections of front mudguard

to slider tube

Nm 3

(Tuflok Blue thread-locking compound; screw

can be released and tightened a number of

times

alternatively: clean thread + Loctite 243)

Headlight bracket to fork bridge Nm 20

Model R 1150 R

Connection

51 Equipment

Mirrors Nm 15

Ignition/steering lock to fork bridge Nm 20

(micro-encapsulated)

Model R 1150 R

Connection

61 General electrical equipment

Horn to holder Nm 8

(clean thread + Loctite 243)

Ground (earth) strap to engine block Nm 9

Battery carrier to rubber-metal element Nm 8

Model R 1150 R

Connection

46 Frame

00.12

Table of operating fluids

Item Use Order number Quantity

Lubricant

Staburags NBU 30 PTM High-performance lubricating paste 07 55 9 056 992 75 g tube

Optimoly MP 3 High-performance lubricating paste 07 55 9 062 476 100 g tube

Optimoly TA High-temperature assembly paste 18 21 9 062 599 100 g tube

Silicone grease 300, heavy Damping grease 07 58 9 058 193 10 g tube

Retinax EP2

Wheel, steering head and taper roller

bearing grease

83 22 9 407 845 100 g tube

Contact spray Contact spray 81 22 9 400 208 300 ml spray

Chain spray Drive chain

72 60 2 316 676

72 60 2 316 667

50 ml spray

300 ml spray

Sealants

3-Bond 1110 B Surface sealant 07 58 9 056 998 5 g tube

3-Bond 1209 Surface sealant 07 58 9 062 376 30 g tube

OMNI VISC 1002 Surface sealant 07 58 1 465 170 90 g tube

Loctite 574 Surface sealant 81 22 9 407 301 50 ml tube

Loctite 577 Thread locking compound 07 58 2 328 736 5 g tube

Curil K 2 Heat-conductive sealant 81 22 9 400 243 250 g can

Adhesives and retaining agents

Loctite 648 Joint adhesive (narrow gap) 07 58 9 067 732 5 g bottle

Loctite 638 Joint adhesive (wide gap) 07 58 9 056 030 10 ml bottle

Loctite 243 Thread retainer, medium-strength 07 58 9 056 031 10 ml bottle

Loctite 270 Thread retainer, strong 81 22 9 400 086 10 ml bottle

Loctite 2701 Thread retainer, strong 33 17 2 331 095 10 ml bottle

Loctite 454 Cyanacrylate adhesive (gel) 07 58 9 062 157 20 g tube

Cleaners

Brake cleaner Brake cleaner 83 11 9 407 848 600 ml spray

Metal Polish Polish for chrome-plated parts 82 14 9 400 890 100 g tube

Testing agents

Penetrant MR 68

Crack testing agent for aluminium

housings

83 19 9 407 855 500 ml spray

Developer MR 70

Crack testing agent for aluminium

housings

81 22 9 407 495 500 ml spray

Installation aids

BMW cooling spray Cooling spray 83 19 9 407 762 300 ml spray

00.13

Contents Page

General view of crated motorcycle ...................................................................................15

Checking the shipping pallet for damage .....................................................................16

In case of damage in Germany ...............................................................................................16

In case of damage in importer markets ..............................................................................16

Unpacking the motorcycle ....................................................................................................16

Installing remaining items on motorcycle .....................................................................16

Mounting the Speedster fairing ..............................................................................................16

Inspecting motorcycle for damage ...................................................................................16

Checking that delivery is complete ..................................................................................16

Filling and charging the battery .........................................................................................17

Removing the fuel tank ...............................................................................................................17

Filling and charging the battery ...............................................................................................17

Checking engine oil when engine is cold, topping up if necessary ...............18

Checking headlight beam angle, adjusting if necessary ......................................19

Checking tightness of rear wheel studs ........................................................................19

Checking tyre pressures .........................................................................................................19

[Integral ABS] Performing bleed test with BMW MoDiTeC ..................................20

Final inspection and function check ................................................................................20

Final cleaning ................................................................................................................................20

Handing over the motorcycle ...............................................................................................21

00 Pre-delivery check

00.14

00.15

General view of crated motorcycle

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BMW R 1150 R Maintenance Manual

Brand: BMW

Model: R 1150 R

Category: Motorcycles

Type: Maintenance Manual

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BMW R 1150 R Maintenance Manual

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BMW R 1150 R Maintenance Manual

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